Building blocks

ABSTRACT

The present invention is a block having an elongated and hexagonal shape. A central void runs through the block. The block is formed of an elastomeric and water-repellant material. The hexagonal shape facilitates stacking of blocks having identical hexagon dimensions, although the elongated dimension, or length, of the blocks may be different. The central void of the block may be filled with one or more materials that impart additional characteristics to the block and the resulting structure.

FIELD OF THE INVENTION

This invention relates to components for construction generally, and ismore specifically directed to building blocks for constructing and/orsupporting walls, barriers, dams and the like.

BACKGROUND OF THE INVENTION

Barriers, such as walls, dams, fences and other similar structures arecommonly formed of a plurality of blocks. The blocks may be formed ofmasonry materials, ceramics, metals and other materials.

There is a need for building blocks that are formed of shapes that areeasily stacked, and easily connected. There is a need for blocks havingelastic properties that are sufficiently rigid to bear substantialloading. Preferably, the blocks are made of commonly available andrecyclable materials.

SUMMARY OF THE INVENTION

The present invention is a block having an elongated and hexagonalshape. A central void runs through the block. The block is formed of anelastomeric and water-repellant material.

The hexagonal shape facilitates stacking of blocks having identicalhexagon dimensions, although the elongated dimension, or length, of theblocks may be different. The central void of the block may be filledwith one or more materials that impart additional characteristics to theblock and the resulting structure. The central void of the block may befilled with a material that resists deformation under load, or whichresists impact or which absorbs energy, for example.

A plurality of the blocks may be used to form a barrier, such as a wall,bridge, fence or dam. The blocks may be used to support or stabilizestructures. The blocks may reflect solid materials and/or liquidmaterials and/or absorb energy, including impact and acoustic energy, oract as a conduit for water or other liquids.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a building block according to anembodiment of the invention.

FIG. 2 is an elevation showing a hexagonal first end of a building blockaccording to an embodiment of the invention.

FIG. 3 is a side elevation of a building block according to anembodiment of the invention.

FIG. 4 is a sectioned view of the building block shown in FIG. 3.

FIG. 5 is a sectioned view of the building block of FIG. 4, showing acentral void of the building block filled with foam.

FIG. 6 is a sectioned view of the building block of FIG. 4, showing acentral void of the building block filled with soil.

FIG. 7 is a sectioned view of the building block of FIG. 4, showing acentral void of the building block filled with concrete.

FIG. 8 is a sectioned view of the building block of FIG. 4, showing acentral void of the building block filled with aggregate, such as rock,gravel or stone.

FIG. 9 and FIG. 10 demonstrate connection of multiple building blocksalong a common longitudinal axis by a connector located in the centralvoid.

FIG. 11 and FIG. 12 demonstrate alternate embodiments of structuralreinforcing material placed within the building blocks.

FIG. 13 is a sectioned view of the building block of FIG. 12.

FIG. 14 is a perspective view of an embodiment of a building block witha connecting member attached to an end of the building block.

FIG. 15 is an elevation of the first end of the building block of FIG.14.

FIG. 16 demonstrates a side elevation of the building block of FIG. 14.

FIG. 17 is an isolation of the connector of the building block of FIG.14.

FIG. 18 demonstrates use of the building block of FIG. 14.

FIG. 19 shows a plurality of stacked building blocks according to anembodiment of the invention.

FIG. 20 demonstrates a stacking configuration for the building blocks.

FIG. 21 presents an alternative stacking configuration for the buildingblocks.

FIG. 22 demonstrates yet another stacking configuration for the buildingblocks.

FIG. 23 demonstrates still another stacking configuration for thebuilding blocks.

FIG. 24 demonstrates adjoining building blocks with the axis of thecentral void in a vertical configuration.

FIG. 25 demonstrates an alternative use of the building blocks.

FIG. 26 demonstrates a building block having a plurality of holes thatconnect the central void with an exterior of the building blocks.

FIG. 27 is a perspective view of an embodiment of the building blockshowing alignment marks on the block.

FIG. 28 is an elevation of an end of an embodiment of the building blockshowing alignment marks on the block.

FIG. 29 is a perspective view of an embodiment of the building blockshowing arcuate corners formed where the sides of the block meet.

FIG. 30 is an elevation of an end of an embodiment of the building blockshowing arcuate corners formed where the sides of the block meet.

FIG. 31 is a top plan view of a structure that may be used for vehicularcontrol.

FIG. 32 is a partially sectioned elevation of a structure with blockspositioned under a rigid base with ends of the blocks aligned with thecentral voids forming a conduit.

FIG. 33 is a bollard formed by a block or blocks positioned verticallyand filled or partially filled with a material such as concrete.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention is a building block component that is useful inbuilding a structure. The building blocks may be used to support orstabilize structures. The blocks may reflect solid materials, and repelliquid materials and/or sound waves. The blocks comprise a hexagonalshape about an outer perimeter, and have a central void, which may beround. The central void may be filled with a second material, which maybe concrete, metal, earth, rock aggregate, synthetic material or acombination thereof.

The blocks are preferred to be made of an elastomeric and waterrepellant material. The blocks may be made from natural or syntheticrubber. The rubber may be crumb and/or buffing material, which may bederived from automotive tires, and preferably, used tires. Otherproducts, such as fly ash and/or cement may be added to the crumb andbuffing mixture to increase density of the material.

FIG. 1-FIG. 4 show a building block 2 of a preferred embodiment. Thebuilding block as shown has an equilateral hexagonal outer perimeter,with the overall block being elongated from each end. The block isformed of an elastomeric and water repellent material. The block iselongated in shape, having a length as desired. The minimum dimensionfor blocks that are useful in building structures as contemplated by theinvention is 15 centimeters measured from one flat side that makes upthe hexagon of the block to an opposite flat side of the block.

The block has a central void 4. In a preferred embodiment, the centralvoid has a round cross-section that is perpendicular to the central axisof the round void. The central void may be cylindrical, and extend froma first end to an opposite or second end of the block. The central voidmay open at one or both ends of the block, and closed at or near one orboth ends of the block. The round cross section provides excellentstructural loading characteristics to the block, while being easy tomanufacture and easy to fill with a material. The central void may be ofothers shape as desired by the user. The central void is preferred tohave a diameter of not less than 5 centimeters. The wall thickness ofthe block with a central void is preferred to be not less than 1.5centimeters.

The use of an equilateral hexagonal perimeter, along with a roundcentral void, yields a structure that can be oriented with any of thesix sides positioned up or down, and in any of the six positions, whileproviding substantially identical structural integrity in anyorientation.

FIG. 5-FIG. 8 demonstrate the central void filled with variousmaterials, such as foam 32, soil or earth 34, concrete 36, or aggregate38. Filling the central void with other materials modifies thestructural characteristics of the block. Additional rigidity can beprovided by filling the central void with aggregates, including rock,stone or concrete. Such materials are readily available, but are heavyto transport. Accordingly, the building blocks may be shipped with thecentral void empty, thereby reducing the shipping weight, with thecentral void filled with the second material at the construction site.The central void of the building blocks acts as a mold and/or containerfor the second material.

The central void may be filled with materials such as sand, earth orsoil; foam, such as flowable polyurethane foam; aggregates, such asgravel or rock; and materials such as concrete or grout that areflowable and harden.

The blocks may be used in combination to form a structure that resistsimpact by the absorption of energy from the impact. The central void ofthe blocks may be filled with energy absorbing materials that arecompressible upon impact. Such materials include foam, such as closedcell and open cell foam, and flowable foam, including polyurethane foam.Sorbothane®, Bubble Wrap, and other energy absorbing materials may beused alone, or in combination. Some or all of the blocks may be filledwith one or more of these materials.

The blocks may be used in combination to form a structure that absorbssound energy from impact, or to form an acoustic barrier. The centralvoid of the blocks may be filled with materials that absorb soundenergy. Such materials include foam as described above; fibers, such asmatted or spun fibers; materials having an impervious surface mountedover an airspace; and resonators connected to an enclosed volume oftrapped air. Some or all of the blocks may be filled with one or more ofthese materials.

The blocks may be joined end-to-end by the use of a connector. Theconnector is preferred to have substantially the same shape as thecentral void. As demonstrated in FIG. 9 and FIG. 10, the connector maybe a round, generally cylindrical shape, yielding what may be describedas a pin 6. The pin is inserted into a first block with a portionextending into a second, and adjoining block. The pins may build up inthe central void by interference fit. The blocks are then assembledend-to-end as shown in the drawing figures.

One or more reinforcing materials may be added to the rubber structureto provide additional support and structural integrity to the walls ofthe blocks. Reinforcement may be accomplished, for example, by placingfibrous material, which may be a synthetic material, into the rubberstructure, or by placing composite rings 8, 12 or spirals 10 into therubber structure, or by placing steel reinforcement bars into the rubberstructure. FIG. 11, FIG. 12, FIG. 13. The reinforcing material may bemetal rings or spirals of various dimensions. The rings or spirals maybe positioned along the length of the blocks as needed or desired, and aseries of rings, or one or more spirals, may extend entirely, orpartially, from a first end of the void to the second end of the void.Particularly where the building blocks have an open central void, foruse as a conduit or a storage cavity, it is not desirable to fill thecentral void with a second material, and reinforcement materials such asrings or spirals are preferred. The reinforcing materials may besynthetic fibers, such as aramid and/or nylon fibers, compositematerials, or metals such as steel or other alloys, such as stainlesssteel that resists corrosion. The blocks may be reinforced by addingmetal strands, or rebar to the elastomeric material. The reinforcingmaterials may be placed longitudinally, and generally parallel to thelongitudinal axis of the central void, or may be otherwise positioned toprovide strength as required according to the application for theblocks.

In one embodiment, a connector 14 may be present on an end of thebuilding blocks. The connector is designed to engage either anotherbuilding block having a void shaped so as to receive the connector (FIG.14), or the connector may be present on another structure, with theblock having a void to receive the connector. FIG. 18. The connector maybe of various shapes and configurations. A connector 14 having a sixpointed star shape is demonstrated by FIGS. 14-18. The six pointed starshape is particularly adapted to align with and be held within thefemale six pointed star shape void 20 of the building blocks as shown inthe drawing figures. The pins 16 extending from the connector thatengage the building block hold the connector firmly in place. As shownin FIG. 18, a plurality of building blocks may be connected to anotherstructure, such as a wall, in which a connector, such as connector 14,is mounted, by void 20 of the building blocks.

A structure may be formed by positioning the blocks with sides of ablock adjoining one or more sides of other blocks having the samehexagonal dimensions. FIG. 19 shows the building blocks used to form aportion of a wall or other similar structure. While FIG. 19 shows theblocks in a two-block by five-block arrangement, the overall height andwidth of a wall, fence or other structure may be formed to the heightand width desired by the user. The central void may be filled with asecond material as described herein to achieve desired structuralcharacteristics, or the central void of the block may be left open tofacilitate the flow of liquid materials there through, or to allow forexpansion and contraction of the blocks, or to use the void as storagefor objects or devices. A honeycomb structure as shown may beconstructed to the desired height and length through the use of multipleblocks as required.

The length of the blocks may be identical in one application. However,in other applications, the length of the blocks may not be identical, asshown in FIG. 20. In FIG. 20, the blocks are of unequal length, and areused as a wall that is adjacent to a material, which could be soil 22,concrete or other material. For example, the wall may be used hold thesoil or other material to prevent collapse, or retard the soil or othermaterial from eroding. In FIG. 20, the blocks are positioned so that afront face of the blocks is flat. However, in FIG. 21, the blocks are ofunequal length, and are stacked in a configuration so that the blockshave a staggered face on each end of the blocks. Soil 22 or othermaterial is on either side of the wall or structure formed by theblocks, with the blocks supporting or separating the soil or othermaterial, or adding structure to soil or other material. Designs orconfigurations may be formed by staggering the blocks. Ends of theblocks may be cut or shaped to form a desired shape in the overallconstruct.

FIG. 22 demonstrates an arrangement of the blocks wherein the blocks areattached to an object, such as a rigid and planar base, and suspendedthere from. In the particular embodiment as shown, the blocks aresuspended from a wooden beam or wooden deck 24. Known fasteners andconnection devices may be used to connect the blocks. Alternatively, theblocks may support the object, such as a rigid and planar base 24. FIG.32. The blocks may form decking for a bridge, wherein the decking is thebase, which may be planar and rigid in form for pedestrian or vehiculartraffic. If the central void is left open, the blocks provide a conduit45 for liquid flow through the blocks. Blocks may be positioned and/orjoined end to end so that the central voids align and form a conduit.

FIG. 23 demonstrates the building blocks stacked in an irregularformation. A first end of some of the plurality of blocks is recessedrelative to a first end of others of the plurality of blocks as theplurality of blocks is stacked to form a structure.

FIG. 24 demonstrates the blocks with the axis of the central voidextending vertically. For demonstration purposes as shown, the buildingblocks are used as a planter, with soil present in the central void, andplants 26 growing in the soil in the central void. Vertically positionedblocks may also be used as pavers, and may be filled with soil, sand,concrete, rock or other materials. The top surfaces of the blocks arepreferred to be in substantially the same plane when used to form adriveway or walkway or similar structure when used as pavers.

The blocks may be used to form barriers such as vertically extendingbollards 46. FIG. 33. The blocks, which are relatively light in weight,may be positioned, then filled with materials to anchor the blocks. Forexample, the block may be positioned in front of another structure thatthe block protects, such as a parking ticket dispenser in a parkinggarage, and filled with concrete 48 after positioning to anchor theresulting bollard.

FIG. 25 demonstrates a building block's central void used for storage ofa device or object. In this case, the building block is used for storageof a wine bottle 28. The blocks can be stacked as demonstrated herein toform a storage rack and to provide storage for multiple bottles of wineor other objects.

FIG. 26 identifies a building block 102 having a plurality of voids 106that extend from the exterior of the building block into the interior ofthe central void 104. Holes or voids such as these may be used as weepholes for drainage of one or a plurality of blocks. The plurality ofblocks may be drained by aligning the weep holes. Again, it is preferredthat the six sides of the blocks are equilateral and substantiallyidentical, so that positioning and/or stacking of the blocks iseffective no matter which side is placed up or down when stacking theblocks. By aligning the holes, and filling the central void with aflowable material that hardens, a plurality of adjoining blocks may beconnected by the flowable material. The flowable material could be apolyurethane or similar hydrogen reactive material, such as thosecomprising isocyanate, or grouting materials, or concrete.

As shown in FIG. 27 and FIG. 28, alignment marks 40 may be etched orformed or printed on the blocks. In a preferred embodiment, there aresix alignment marks, with one alignment mark corresponding to each sideof the blocks and formed halfway along the length of the side. Thealignment mark may be aligned with the alignment mark of an adjoiningblock to assist alignment and assembly of the structure.

FIG. 28 and FIG. 29 demonstrate an embodiment of the blocks havingrounded or arcuate corners 42, rather than sharp corners.

FIG. 31 demonstrates a structure that may be used as a funnel for a flowof traffic or materials. For example, the structure may provide atraffic barrier that extends into a lane of traffic, with the pluralityof unequal length blocks mounted at an angle, such as a 30° to 60°angle, on a vertical structure, such as a wall or barrier 44. Theresilient nature of the blocks absorbs impact in the event that theblock is struck by a vehicle.

The maximum length of a block is limited only by manufacturing andtransportation criteria. Dimensionally, the size of a block will bedetermined by the design of each specific project detail, for example, apaver type block may have a parallel sides dimension of 8 inches with acentral void diameter of 6 inches, whereas a unit to be used in awaterway may have an exterior dimension of 24 inches with a central voiddiameter of 18 inches. The block may be manufactured by compressionmolding, injection molding, or extrusion or pultrusion techniques.

The block according to the invention is substantially lighter in weightthan concrete or masonry blocks of corresponding size. The block can beeasily carried by a person and positioned as required to form astructure with the blocks. The central void can be filled with concreteor other materials as described herein after assembly of the blocks inmany cases.

1. A structure formed of building blocks, comprising: a plurality ofblocks, wherein each of the blocks of the plurality of blocks consistsof six sides that surround a central void, wherein the central voidextends from a first end of each of the blocks to a second end of eachof the blocks, the six sides forming an equilateral hexagonal shape atthe first end of each of the blocks and an equilateral hexagonal shapeat the second end of the each of the blocks, and wherein one of the sixsides of each of the blocks contacts one of the six sides of another ofthe plurality of blocks; wherein each of the blocks is a solid andunitary member formed of an elastomeric and water repellent material. 2.A structure formed of building blocks as described in claim 1, whereinthe central void of each of the blocks comprises an inelastic material.3. A structure formed of building blocks as described in claim 1,wherein the elastomeric and water repellent material is rubber.
 4. Astructure formed of building blocks as described in claim 1, wherein thecentral void of each of the blocks comprises an aggregate.
 5. Astructure formed of building blocks as described in claim 1, wherein theelastomeric and water repellent material comprises a reinforcingmaterial.
 6. A structure formed of building blocks as described in claim1, wherein a first end of one of the plurality of blocks is recessedrelative to a first end of another of the plurality of blocks thatadjoins and contacts said one of the plurality of blocks.
 7. A structureformed of building blocks as described in claim 1, wherein a first endof each of the plurality of blocks is positioned relative to another ofthe plurality of blocks to form an irregular surface configuration inthe structure formed of building blocks.
 8. A structure formed ofbuilding blocks as described in claim 1, further comprising a weep holethat extends through a block of the plurality of blocks from an exteriorof the block to the central void of the block.
 9. A structure formed ofbuilding blocks as described in claim 1, wherein a block of theplurality of blocks is positioned over a rigid base, and a central axisof the central void of the block extends generally vertically from therigid base.
 10. A structure formed of building blocks as described inclaim 1, wherein at least two blocks of the plurality of blocks arepositioned under a rigid base and provide support for the rigid base,and a central axis of the central void of each of the at least twoblocks extends generally vertically.
 11. A structure formed of buildingblocks as described in claim 1, wherein at least two blocks of theplurality of blocks are positioned under a rigid base and providesupport for the rigid base, and a central axis of the central void ofeach of the at least two blocks extends generally vertically, andwherein an end of at least one additional block of the plurality ofblocks joins an end of another block of the plurality of blocks so thatthe central voids thereof align and form a conduit.
 12. A structureformed of building blocks as described in claim 1, wherein an end of ablock of the plurality of blocks joins an end of another block of theplurality of blocks so that the central voids thereof align and form aconduit.
 13. A structure formed of building blocks as described in claim1, wherein the central void of the plurality of blocks comprises acompressible and energy absorbing material.
 14. A structure formed ofbuilding blocks as described in claim 1, wherein the central void of theplurality of blocks comprises an acoustic energy absorbing material. 15.A structure formed of building blocks as described in claim 1, wherein ablock of the plurality of blocks is positioned over a base, and acentral axis of the central void of the block extends generallyvertically from the rigid base, and wherein the central void is filledwith concrete to form a bollard.
 16. A structure formed of buildingblocks as described in claim 1, wherein a central axis of the centralvoid of at least two blocks of the plurality of blocks extends generallyvertically, and the plurality of blocks forms a wall.
 17. A structureformed of building blocks as described in claim 1, wherein a centralaxis of the central void of at least two blocks of the plurality ofblocks extends generally vertically, and the top surfaces of the atleast two blocks are in substantially the same plane.
 18. A structureformed of building blocks as described in claim 1, wherein theelastomeric and water repellent material comprises an elastomericmaterial obtained from recycled tires.
 19. A structure formed ofbuilding blocks as described in claim 1, wherein the central void is acylindrical void.